TENDER FOR CENTRALIZED FOAM SYSTEM (CFS) PHASE II AUTOMATION ASSOCIATED WORKS AT BPCL MIRAJ DEPOT

ANNEXURE VI - TECHNICAL SPECIFICATIONS & SCOPE OF WORK

SUBJECT: TENDER FOR CENTRALIZED FOAM SYSTEM (CFS) PHASE II AUTOMATION AT BPCL MIRAJ DEPOT.

1. S/L/C of 12 core 1.5 sq. mm control cable for mother foam tank motors and SOVs (C/R to JB)

2. S/L/C of 2 core 1.5 sq. mm control cable for SOV's (from JB to SOV):

Qty: 775 Metre.

3. S/L/C of 12 pair 1.5 sq.mm signal cable from C/R to JB for Level Switch:

4. S/L/C of 2 pair 1.5 sq.mm signal cable- JB to Level switch:

Qty: 515 Metre.

5. S/I/C of FLP Solenoid Operated Valve (SOV) 1.5" & 2.0” 230 V AC for foamline:

Qty: SOV- 2 inch : 1 Nos.

SOV- 1.5 inch : 2 Nos

6. S/I/C of Level switch top mounted probe type for daughter foam tanks:

7. Explosion Proof/ Weather proof Junction Box:

JB Specification & Quantity Requirement

Size: 250mm X 250mm

Input Entry : Cable Size- 12P X1.5 Sq. MM

(25 mm - 2 Entries)

Output Entry: Cable Size- 2PX1.5 Sq. MM

 Supply and installation of JB Glands will

be under the scope of successful bidder.

Gland, size 19mm = 35 Nos

Gland, size 25mm = 6 Nos

Blind, size 19mm = 10 Nos

Blind, size 25mm = 2 Nos

 Location for installation of JB will be given by Engineering Officer.

8. S/F of GI cable trays for control cables:

9. Supply and erection of SS 304 Ball valve 1.5 " & 2.0” for SOV bypass and foam tank isolation:

Qty: SS Ball valve 1.5 inch - 15 Nos

SS Ball valve 2 inch - 2 Nos

CS Ball valve 2 inch - 6 Nos

10. Supply and laying of SS 304 1.5" & 2.0” pipe for bypass line at daughter tank.

Supply, fabrication including cutting; edge preparation; fit up; welding and erection of above ground

pipeline over existing pedestals; overheads on racks and at all elevations; connecting with equipment

nozzles; tapping for pressure gauges; sample connection; etc. using approved make and suitable

welding electrode.

11. Supply and fabrication of SS Elbow 1.5"& 2.0”

Qty: SS Elbow 1.5 inch - 30 Nos

SS Elbow 1.5 inch - 06 Nos

12. Supply and fabrication of CS Elbow 2.0”

Qty: CS Elbow 2.0 inch – 12 Nos

13. Supply and Installation of SS Non-Return (2.5”) Valve for foam line of HVLR (i.e., Foam line- AFFF & Foam

Qty: SS Non-Return (2.5”) Valve – 4 Nos

14. Supply and fabrication of SS Flange 1.5" & 2” for fixing, ball valve, NRV, SOV and Radar Gauge:

Qty: SS Flange 1.5” - 60 Nos (1.5” SOV, 1.5” Ball valve)

SS Flange 2.0“ - 12 Nos (2”SOV, 2” Ball valve, Radar Gauge)

SS Flange 2.5” - 08 Nos (NRV)

15. Fabrication, welding of the supplied 3" SORF (free issue material by BPCL)

16. Supply and fabrication of CS Flange 2.0" for ball valve & SOV:

17. Charges for making flanged joints 1.5” & 2.0”

Qty: 1.5” Flanged Joints - 30 Nos

2.0” Flanged Joints - 18 Nos

18. Painting Specification:

Surface Preparation:

Heavy Scrapping and surface preparation up to SSPC SP2 or St.3. (External surface of Pipeline as specified).

Mechanical Cleaning manually shall be done by brass wire brush, emery/sandpapers etc as instructed by

Engineer-in-charge. Removing oil, dust, grease, mill scale and moisture and making the surface dry including all

materials, consumables, labour; scaffolding; equipments etc. complete. Rate shall be paid in M2 basis of the

scrapped surface

(Note : Scaffolding shall be paid separately).

Supplying and applying primer on the prepared surface including all labor; scaffolding; consumables; equipments;

primer etc. complete as per specifications (primer shall be applied within 8 hours of surface preparation). Paint

shall be as per attached list of BPCL recommended manufacturers. Two coat of surface tolerant epoxy mastic

coating at 125 microns per coat. Rate shall be paid in M2 basis of the painted surface.

(Note : Scaffolding shall be paid separately).

Supplying and applying finish paints on the prepared pipe surface including all labor; scaffolding; consumables;

equipments; primer etc. complete as per specifications. Paint shall be as per attached list of BPCL recommended

Finish Coat: Two coats of acrylic aliphatic polyurethane at 30 microns/coat in Yellow/golden yellow shade as per

IS : 5. Rate shall be paid in M2 basis of the painted surface.

19. Pipelines supports with PCC for pipeline/SOVs/JBs/cable trays etc.:

Providing and laying PLAIN CEMENT CONCRETE for all depths below and up to plinth level in foundations, drains,

fillings, non-suspended floors, pavements & ramps or any other works etc. including the cost of position cement

concrete of specified grade including the cost of centering and shuttering, tamping, ramming, vibrating, curing,

in any shape, position, thickness and finishing the top surface rough or smooth, etc. all complete as per directions

of Engineer-in-charge.1:2:4 (1 Cement: 2 coarse sand: 4 graded stone aggregate 20 mm nominal size)

20. Structural steel support work pipeline/SOVs/JBs/cable trays etc:

Supply, fabrication and erection in position; bolted and/or welded structural steel works at all levels; including all

built-up sections /compound sections made out of rolled sections and / or plates in trusses; rafters; purlins; wind

ties; columns; portals; platforms; staircases; (excluding chequered plates, swing ladders, foundation bolts and

gratings) ladders; stoppers; brackets sag rods; supports for equipment and accessories; hand railings posts cutting

to required size as per approved drawings; straightening if required bolting/ welding of joints (including sealing

the joints of the box sections with continuous welding wherever specified) finishing edges by grinding; fixing in

line and level with temporary staging and removal of same after erection; grouting with ordinary grout or non-

shrink grout as specified; including preparation of detailed fabrication drawings, cost of painting as specified

below, complete in all respect as directed by Engineer-in-charge. Cost of nut & bolts to be borne by contractor.

21. Supplying & Fixing 150 # CS Butterfly valve of size 3”, 4” & 6”

Qty: Butterfly valve 3”- 2 Nos

Butterfly valve 4”- 2 Nos

Butterfly valve 6”- 2 Nos

22. Supply and fixing of acrylic tubing for daughter foam tank level indicator (1/2")

The functionality of control panel to be programmed is described as below:

a. Shall host power supply to field instruments (230V in case of SOVs, 24V DC if required in case

of liquid level switches)

b. Shall have option for mother tank selection and pump selection (main + standby) to be used for

auto foam feeding.

c. Shall give audio/visual alarm on reaching the low level in any of the mother tanks

d. Receive feedback from liquid level switches of daughter foam tanks

e. Shall give open command to the SOV of the selected mother tank and that of daughter tank in

which foam level drops below low level (as per feedback from liquid level switch).

f. Based on SOVs opened for daughter tanks, the panel shall give a visual indication for the

daughter foam tanks being topped up.

g. Shall give start command to pump for foam pumping.

h. Shall give stop command to the SOV of daughter tank when foam level reaches high level (as

per feedback from liquid level switch).

i. Shall give stop command to pump once all the SOVs of daughter tanks to be topped up

has closed/high level reached in all daughter tanks.

j. Shall give close command to the SOV of mother tank, once close command to pump of mother

# The basic setup for auto foam feeding system is depicted by the block diagram below:

# The basic setup for auto foam induction system for HVLRM is depicted by the block diagram below:

Supply & Fabrication works Qty UoM

Supply and fabrication of SS 304 1.5" pipe for bypass line at

daughter foam tank CFS and HVLR

Supply and fabrication of SS 304 2" SS pipe for bypass line at

mother foam tank and stub for fixing RADAR Gauge.

Supply and fabrication of 2" MS pipe for bypass line at

daughter tank (Water line SOV bypass HVLR)

S/I/C of FLP solenoid operating valve (SOV) 1.5" 230 V AC for

daughter foam tanks

S/I/C of FLP solenoid operating valve (SOV) 2.0" 230 V AC for

mother foam tanks

Supply and erection of SS ball valve 1.5 " for SOV bypass and

foam tank isolation

Supply and erection of SS ball valve 2.0 " for SOV bypass and

foam tank isolation.

Supply and erection of CS ball valve 2.0 " for SOV bypass and

foam tank isolation.

Supply and fabrication of SS Flange 1.5" SS for ball valve &

Supply and fabrication of SS Flange 2.0" for SS for ball valve &

10 SOV, 10 Nos and for mounting RADAR Gauge on Mother 12 24 IND

foam tank: 2 Nos

Supply and fabrication of CS Flange 2.0" for ball valve & SOV,

12 Supply and fabrication of SS Flange 2.5" for NRV fixing 8 20 IND

Charges for making flanged joints/fixing blind flanges class

13 150 lb including supplying and fixing of metallic spiral gasket, 30 45 IND

Charges for making flanged joints/fixing blind flanges class

14 150 lb including supplying and fixing of metallic spiral gasket, 18 36 IND

15 Supply and fabrication of SS Elbow 1.5" , 30 Nos 30 90 IND

16 Supply and fabrication of SS Elbow 2.0", 6 Nos 6 24 IND

17 Supply and fabrication of CS Elbow 2.0" , 12 Nos 12 48 IND

Supply and Installation of SS NON RETURN VALVE as per BPCL

enclosed specifications including supplying of 3mm CAF

gasket; studs / bolts (ASTM A 193 Gr B7) & nuts ( ASTM

Gr 2H) of recommended brands

Supplying & Fixing 150 # CS Butterfly valve with

19 wheel/handle including supplying of 3mm CAF gasket; studs / 2 6 IND

Supplying & Fixing 150 # CS Butterfly valve with

20 wheel/handle including supplying of 3mm CAF gasket; studs / 2 8 IND

Supplying & Fixing 150 # CS Butterfly valve with

21 wheel/handle including supplying of 3mm CAF gasket; studs / 2 12 IND

S/I/C of Level switch top mounted probe type for daughter

S/L/C of 12 core 1.5 sq. mm control cable for mother foam

S/L/C of 12 core 1.5 sq. mm control cable for SOV's (from C/R

S/L/C of 2 core 1.5 sq. mm control cable for SOV's (from JB to

S/L/C of 12 pair 1.5 sq.mm signal cable from C/R to JB for

27 S/L/C of 2 pair 1.5 sq.mm signal cable- JB to Level switch 515 515 RM

S/F of GI cable trays for signal cables & control cables (if no

trays running for existing TAS equipments)

S/I of FLP junction box including glands, blinds, no. of entires,

29 TBs as per the technical specifications mentioned in 4 4 NO

Pipelines supports with PCC for pipeline/SOVs/JBs/cable trays

Structural steel support work pipeline/SOVs/JBs/cable trays

SS foam pipeline & Foam tank painting (epoxy+yellow enamel)

Heavy Scrapping and surface preparation, shall be done by

32 brass wire brush, emery/sand papers etc as instructed by 50 50 M2

Engineer-in-charge.

Supplying and applying primer on the prepared surface

33 including all labour; scaffolding; consumables; equipments; 50 50 M2

Supplying and applying finish paints on the prepared pipe

34 surface including all labour; scaffolding; consumables; 50 50 M2

equipments; primer etc. complete as per specifications

Modifications in Daughter foam tank manhole/ cover for fixing

Fabrication, welding of the supplied 3" SORF (free issue

material by BPCL), 150# on the pipelines / fittings using

approved make / size of welding electrode.(For mounting

level switches on daughter foam tanks)

Fabrication of 3" pipe/stub for fixing level switch on daughter

Supply and fixing of Acrylic tubing for daughter foam tank

level indicator (1/2")

Note: The quantity mentioned above is calculated on theoretical basis and may vary after the completion

of work. However, final payment shall be made based on actual work done at site.

The above services/works including supply, installation, commissioning has to be completed within the

stipulated time period (21 days) as mentioned in the tender documents. Delay in completion of the subject

jobs/ services/ works will be subjected to penalties or even termination of the contract without any prior

PPEs should be worn by contract workmen during work execution.